Method and apparatus for fabricating contoured laminate structures

ABSTRACT

A plurality of identical fabrication modules are linked together and configurable to fabricate any of a plurality of differing laminate structures in a family of structures having common features. Each of the fabrication modules is locally adapted to fabricate a section of the laminate structure on a corresponding tool. A controller controls and coordinates automated operation of the fabrication modules.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Provisional U.S. PatentApplication No. 61/749,881 filed Jan. 7, 2013, which is incorporated byreference herein in its entirety.

BACKGROUND INFORMATION

1. Field

The present disclosure generally relates to fabrication of laminates,especially those that are contoured, and deals more particularly with amethod and apparatus for automated layup and forming of differentlaminate structures within a family of structures having commonfeatures.

2. Background

Composite structures, especially those having contours, sometimes havefeatures that require that the structure be formed of multiple parts.For example, in the aircraft industry, contoured composite fuselagebarrel frame sections may be formed using a two-piece assemblycomprising a channel section frame and a shear tie, mechanicallyfastened together. More recently, one-piece composite frame sectionshave been proposed that employ braided composites, however thisfabrication approach is time consuming and labor intensive, and mayresult in a frame that is heavier than desired. The problem offabricating one-piece frame sections is more difficult in highproduction rate environments where production flow times may beimportant to achieve manufacturing efficiencies.

Accordingly, there is a need for a method and apparatus for producingone-piece laminate structures, especially those that are contoured,which reduce labor and assembly time through automation. There is also aneed for a method and apparatus for producing different laminatestructures within a family of structures having common features in orderto reduce material and labor costs while increasing production rates.Furthermore, there is a need for a method and apparatus for fabricatinglaminate structures using certain material forms such as unidirectionalpre-preg tape, that may not be producible using conventional, manualfabrication methods.

SUMMARY

The disclosed embodiments provide a method and apparatus for producingdifferent composite laminate structures within a family of structureshaving common features. The apparatus comprises an automated,reconfigurable composite forming system especially designed to formunidirectional pre-preg tape in the production of structural members,such as aircraft fuselage frames. The apparatus comprises a plurality ofsubstantially identical forming modules linked together to form a singleformer that may be reconfigured to conform to a wide range of toolsdefining corresponding structural shapes. Each of the forming modulespossesses the ability to locally adapt or transform to the uniquedesign, shape or features of the tool. In one aircraft application, theapparatus may be employed to fabricate multi-ply composite framesections having a Z cross-sectional shape, by laying up, forming andcompacting each ply of the frame section. The plies are formed from aninner chord outwardly to an outer chord, sometimes referred to as ashear tie. Each of the forming modules adapts to the local shape of thetool. The modules are linked together in a manner to form a singleformer that adjusts to the entire tool. Different tool arc lengths canbe accommodated by adding or removing forming modules. It is notnecessary that the forming modules exactly match the total arc length ofa tool in those cases where the structure is contoured. The apparatusemploys an adaptive control system based on a generic structural shapeprofile of structures within a family of structures. The adaptivecontrol system forms each ply of the structure based on a combination offorce feedback and positional control. Each forming module has two servoaxes and employs force feedback on one of these two axes at a time. Theuse of force feedback is dependent upon the area of the structure beingformed. During the forming process, the feedback switches back and forthbetween the two axes. Switching between the two axes is controlled bythe adaptive system and is determined by generic shape parameters of thestructure being formed. Reliance on a generic motion profile allows theapparatus to form any of a multiplicity of unique structures, ply-by-plywithout the need for NC (numerical control) programming. The apparatusis easily scalable to fabricate structures of different sizes within afamily of structures by adding or removing forming modules, andarranging the modules to substantially match corresponding tool shapes.

According to one disclosed embodiment, a system is provided forfabricating a plurality of unique parts. The system comprises aplurality of unique lay-up tools respectively corresponding to theplurality of parts to be fabricated and, a plurality of former modulesconfigured to be combined together to define a plurality of uniqueformers respectively corresponding to the plurality of parts and theplurality of lay-up tools. Each of the formers is adapted for layingdown material on a corresponding one of the lay-up tools to form acorresponding one of the parts. The former modules are substantiallyidentical, and each of the plurality of unique formers is configured bycoupling each of the substantially identical former modules to thecorresponding unique lay-up tool. The former modules are linked togetherand are mounted on bases allowing the former modules to move in multipledirections. Each of the former modules includes a forming head adaptedto form the material on a corresponding one of the lay-up tools. Each ofthe forming heads includes compliance. The part may be a laminatedstructure, and the laminated structure may be a carbon fiber reinforcedplastic.

According to another disclosed embodiment, apparatus is provided forfabricating each of a plurality of differing laminate structures in afamily of structures having common features. The apparatus comprises aplurality of separate fabrication modules each locally adapted tofabricate a section of the laminate structure on a corresponding tool.The fabrication modules are reconfigurable to fabricate each of thelaminate structures in the family thereof. The apparatus also includes acontroller for controlling and coordinating automated operation of thefabrication modules. The apparatus may further comprise a forming memberadapted for forming laminate plies over the tool. The forming memberextends along a length of the fabrication modules, and is mounted oneach of the fabrication modules for movement over the tool along atleast two axes. The forming member is continuous along the length of thefabrication modules. The forming member is controlled along two axes,but has a shape that adapts to changes between different areas of thestructure being formed, such as, in the case of a one-piece aircraftfuselage frame, between an inner chord radius and a shear tie radius ofthe frame. Each of the fabrication modules includes a track in which aportion of the forming member is locally mounted. A single formingmember may be used to fabricate a particular structure, however theforming member is removably mounted in the track to allowinterchangeability of a plurality of forming members respectively havingdifferent shapes to fabricate differently shaped structures. The trackallows for lateral (or tangential) slip of the forming member relativeto each module as the arc length of the structure changes as the formingmember moves over the structure. The forming member is adapted to sweeplaminate plies over the tool, and includes compliance. Each of thefabrication modules includes a clamp adapted for clamping a portion of alaminate ply against a portion of the tool. Each of the fabricationmodules includes a powered drive coupled with the forming member forsweeping the forming member over the laminate plies and compactinglaminate plies on the tool. The apparatus may further comprise aflexible ply carrier adapted to hold at least one laminate ply thereon,wherein each of the fabrication modules includes a pair of spaced aparttracks adapted to releasably hold the ply carrier, and a ply carriercontrol assembly for holding the ply carrier in tension as the formingmember forms the ply over the tool. The forming member is engageablewith the ply carrier to sweep the ply carrier along with the ply thereonover the tool, and the ply carrier control assembly includes drives foradjusting the position ply carrier along two axes. Each of thefabrication modules further includes a force sensor for sensing a levelof force applied to the laminate plies by the forming member, and aposition sensor for sensing the position of the forming member. Each ofthe fabrication modules further includes a clamp for clamping thefabrication module to the tool. The apparatus may also comprise linkagebetween the fabrication modules for coupling the fabrication modulestogether and for aligning the fabrication modules relative to the tool.The linkage is configured to allow the forming modules to rotate alongan arc that is substantially the same as the retracted arc of thecontinuously extending forming member. The fabrication modules aresubstantially identical and interchangeable with each other. Theapparatus also includes a central controller for controlling andcoordinating the operation of the fabrication modules to collectivelyfabricate the laminate structure.

According to still another embodiment, a method is provided offabricating a plurality of differing parts in a family of parts havingcommon features, wherein each of the parts is fabricated using a uniquetool. The method comprises arranging a plurality of separate,substantially identical fabrication modules to substantially match atool on which one of the parts is to be fabricated, and adapting each ofthe fabrication modules to a local section of the tool. The methodfurther comprises controlling and coordinating operation of thefabrication modules to fabricate portions of the part over acorresponding section of the tool. Arranging the fabrication modulesincludes moving each of the fabrication modules into proximity to thetool, and linking the fabrication modules together. The method mayfurther comprise clamping each of the fabrication modules to the tool.Adapting each of the fabrication modules includes learning, by each ofthe fabrication modules, the location of surfaces on the tool on whichthe part is to be fabricated. The method may also comprise sweepingmaterials across the surfaces of the tool using a forming member, andusing the forming member to learn the location of the surfaces on thetool. Learning the location of the surfaces includes sensing theposition of the forming member as the forming member sweeps materialsacross the surfaces of the tool, and recording the sensed position ofthe forming member. Adapting each of the fabrication modules includesadjusting the elevation of the fabrication modules to a commonwaterline. The method may further comprise forming a continuous splinealong all of the fabrication modules. Forming the continuous splineincludes mounting a continuous forming member along substantially theentire length of the fabrication modules. Each of the fabricationmodules may be a laminate ply former module for forming a local sectionof a ply. Arranging the fabrication modules includes linking thefabrication modules together to form a single laminate ply former.

According to another disclosed embodiment, a method is provided offabricating a composite laminate structure. The method comprisesarranging a plurality of substantially identical forming modules togenerally match a tool on which composite plies are to be formed tofabricate the laminate structure, and linking the forming modulestogether to form a single former for forming an entire compositelaminate structure. The method further comprises mounting a continuousforming member on the forming modules, the continuous forming memberdefining a spline extending substantially the entire length of theformer, and using the forming member to form and compact the compositeplies on the tool. The method may also include placing the compositeplies on a ply carrier. The forming member is used to engage and sweepthe ply carrier along with the plies over the tool.

According to still another disclosed embodiment, a forming module isprovided for forming a composite laminate part over a tool. The formingmodule comprises a base and a ply carrier control assembly adapted forcontrolling the position of a flexible ply carrier on which compositeresin plies are mounted. The forming module further comprises a headsection mounted on the base and adapted for automatically forming thecomposite resin plies from the ply carrier onto the tool. The base isadapted to move over a supporting surface, and the head section includesadaptive control for learning a profile of the tool. The forming modulemay further include a clamp for clamping the head section to the tool,and an automatically controlled forming member for forming the pliesover the tool.

The features, functions, and advantages can be achieved independently invarious embodiments of the present disclosure or may be combined in yetother embodiments in which further details can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and advantages thereof, will best be understood by referenceto the following detailed description of an illustrative embodiment ofthe present disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of a block diagram of a system for fabricatingany of a plurality of parts within a family having common features usingcorresponding tools and fabrication modules according to the disclosedembodiments.

FIG. 2 is an illustration of a diagrammatic plan view of apparatus forfabricating contoured composite laminate structures.

FIG. 3 is an illustration of a perspective view of a composite laminateframe section having a Z-shaped cross-section.

FIG. 4 is an illustration of a cross-sectional view of the frame sectionshown in FIG. 3.

FIG. 5 is an illustration of an end view of a tool having the framesection shown in FIGS. 3 and 4 laid up and compacted thereon.

FIG. 6 is an illustration of a functional block diagram of the apparatusof FIG. 2, shown clamped to the tool illustrated in FIG. 5.

FIG. 7 is an illustration of a perspective view of the apparatus, priorto being moved into proximity to and clamped to a tool, a ply carriernot shown for clarity.

FIG. 8 is an illustration of a front perspective view of three adjacentfabrication modules forming part of the apparatus shown in FIG. 7.

FIG. 9 is an illustration of a front perspective view of one of thefabrication modules shown in FIG. 8, depicting additional details of themodule.

FIG. 10 is an illustration of a plan view of a ply carrier having a plymounted thereon.

FIG. 11 is an illustration of a front view of a nosepiece track formingpart of each of the fabrication modules shown in FIGS. 7-9.

FIG. 12 is an illustration of a perspective view of a portion of thelength of a nosepiece adapted to be mounted on the nosepiece track shownin FIG. 11.

FIG. 13 is an illustration of a flow diagram of a method of fabricatingeach of a plurality of different parts in a family of parts havingcommon features.

FIG. 14 is an illustration of a flow diagram of a method of fabricatinga composite laminate structure.

FIG. 15 is an illustration of a flow diagram of the method used to setup and teach each of the fabrication modules.

FIG. 16 is an end view of the tool shown in FIG. 5, illustrating theprogressive movement of the nosepiece during the set up and teachingphase shown in FIG. 15.

FIG. 17 is illustration of a flow diagram of an adaptive control methodemployed by each of the fabrication modules

FIG. 18 is an illustration of a flow diagram of aircraft production andservice methodology.

FIG. 19 is illustration of a block diagram of an aircraft.

DETAILED DESCRIPTION

Referring first to FIG. 1, a system 38 is provided for fabricating anyof a plurality of unique parts 54 within a family 56 of parts 54 havingcommon features or characteristics. The unique parts 54 may befabricated using corresponding, unique tools 48, which may be layuptools, and a combination 43 of fabrication modules 42, sometimeshereinafter also referred to as former modules 42 or forming modules 42,arranged and configured to form a fabricator 40, sometimes hereinafteralso referred to as a former 40. As will be discussed below in moredetail, the fabrication modules 42 may be identical and interchangeable.The number and arrangement of the fabrication modules 42 is matched tothe particular tool 48 required to fabricate a particular part 54. Thefabricator 40 fabricates the part 54 by placing and forming material 46on the particular tool 48. Forming material 46 may sometimes hereinafteralso be referred to as composite plies 46, pre-preg plies 46, or plies46. In one application, the part 54 may be a multi-ply compositelaminate, and the material 46 may be a carbon fiber reinforced plastic(CFRP). Part 54 may sometimes hereinafter also referred to as compositelaminate 54, composite laminate structure 54, or structure 54.

Attention is now directed to FIG. 2 which illustrates one embodiment ofthe system 38 shown in FIG. 1. In this example, a plurality of formermodules 42 are arranged in a configuration generally matching the shapeof a layup tool 48 on which a particular part (not shown in FIG. 2) isto be formed. In the illustrated example, the former modules 42 arearranged in an arc shape that substantially matches the arc shaped layuptool 48, however, a variety of other shapes are possible. The former 40forms and laminates composite plies 46 on the tool 48. The formermodules 42 are rigidly connected with each other by linkage 44 to form aformer 40. The former 40 self-adapts and aligns itself to eachparticular tool 48 required to make a particular part 54 (FIG. 1). Theformer modules 42 may be substantially identical to each other and arethus interchangeable 50 with modules 42 a purposes of repair,replacement or reconfiguration of the former 40 to form unique partswithin a family of parts having common features or characteristics. Eachof the former modules 42 is coupled with a central controller 52 whichmay comprise a special or general purpose computer, or a PLC(programmable logic controller). The central controller 52 controls andcoordinates the automated operation of the former modules 42.

As previously mentioned, the former 40 may be used to form a variety ofcomposite parts within a family of parts having common features orcharacteristics. For example, referring to FIGS. 3 and 4, the former 40may be used to form and laminate a composite frame section 58 used in anaircraft fuselage (not shown). The frame section 58 is curved orcontoured along its length and has a radius “R”. The former 40 may beused to form any of a range of frame sections 58 having different arclengths, radii or other common features within a family of framesections 58. These features, including contours or radii, may becontinuous or non-continuous along the length of the frame section 58 orother parts being formed. The frame section 58 is generally Z-shaped incross section, and comprises an inner chord flange 62 and an outer chordflange 64 (sometimes also referred to as a shear tie 64). The inner andouter chord flanges 62, 64 respectively are connected by a central web60. The shear tie 64 is connected to the web 60 by a shear tie radius68, and the inner chord flange 62 is connected to the web 60 by an innerchord radius 70. While a Z-shaped frame section 58 has been illustratedin the exemplary embodiment, it should be noted that the disclosedmethod and apparatus may be employed to fabricate composite laminateparts having a variety of other cross-sectional shapes, including butnot limited to L, I and C cross-sectional shapes.

Referring now to FIG. 5, the former 40 forms and laminates compositepre-preg plies 46 on a tool 48. The tool 48 has tool features matchingthe frame section 58. In this example, the tool 48 includes an innerchord tool flange 72, an inner chord tool radius 74, a web tool surface76, shear tie tool radius 78 and an outer chord tool flange 80. The tool48 also includes a clamping flange 82 extending around its entire innerchord. Other types of layup tools 48 may be used in connection with thedisclosed method and apparatus to form other types and sizes compositelaminate parts, having cross-sectional shapes other than Zcross-sections. Moreover, the illustrated tool 48 may be employed tolayup a curved composite laminate frame section or other part having anL-shaped cross-section.

Attention is now directed to FIGS. 6-9 which illustrate one embodimentof the former 40. FIG. 6 is a functional block diagram showing one ofthe former modules 42, in the process of laying up a single pre-preg ply46 on the tool 48. The ply 46 is supported in a desired, or indexedposition on a ply carrier 84 discussed below in more detail. The plycarrier 84 is held along its upper edge on a carrier support track 120at the end of a support arm 95 forming part of the former module 42. Theformer module 42 broadly comprises a ply carrier control assembly 86mounted on a head section 92 which is supported on a movable base 106.The base 106 may include an on-board controller 110 that is coupled withthe central controller 52 (FIG. 2) previously discussed. Wheels orcasters 112 on the base 106 allow the former module 42 to be moved alonga supporting surface such as a factory floor (not shown) in anydirection in order to allow the former module 42 to be positioned in adesired configuration with other former modules 42, such that thecollective geometry of the former modules 42 substantially matches thatof the tool 48. The base 106 includes a Z-axis slide assembly 108 whichmoves the head section 92 and the ply carrier control assembly 86 in thevertical direction, or Z-axis within a machine coordinate system 124.

The ply carrier control assembly 86 controls the attitude of, andtension on the ply carrier 84 in order to support and continuouslyreposition position the ply 46 as it is being formed onto the tool 48.The ply carrier control assembly 86 may include a motorized drive systemwhich moves the support arm 95 and thus the carrier support track 120along both the Y and Z axes. For example, the motorized drive system maycomprise a servo-motor 88 for driving the carrier support track 120along the Y axis, and an air cylinder 90 for driving the support arm 95and the carrier support track 120 along the Z axis. Other drivearrangements are possible.

The head section 92 includes a ply forming member 116, referred tohereinafter as a nosepiece 116, which engages the ply carrier 84 andfollows the shape of the tool 48 to form and compact the ply 46 onto thetool 48. The nosepiece 116 is removably mounted in a nosepiece track 118discussed later in more detail. The nosepiece 116 extends continuouslyalong the entire arc length of the tool 48, and effectively forms aspline between the forming modules 42. Both the nosepiece 116 and thenosepiece track 118 may be flexible along their length to conform to thecurvature and other features of the tool 48. The nosepiece track 118 iscoupled with a motorized drive system which may comprise, for exampleand without limitation, a plurality of air cylinders 102 which move thenosepiece 116 in the Y direction.

Movement of the nosepiece 116 in the Z direction may be effected throughmovement of the head section 92 by the Z-axis slide assembly 108 on thebase 106. The head section 92 further includes an inner chord clamp 122driven in the Y direction by air cylinders 104 or similar motor drives.The inner chord clamp 122 clamps the lower edge of the ply carrier 84and the ply 46 against the inner chord tool flange 72 (FIG. 5) while theply 46 is being formed over other surfaces of the tool 48. The headsection 92 may include a datum locator which may comprise, for exampleand without limitation, a proximity sensor, as well as servo-motors 94and encoders 96. The servo-motors 94 and the encoders 96 may be used todetermine the position of the nosepiece 116, and thus the location ofsurfaces on the tool 48, during an adaptive tool learning processdiscussed below. One or more load cells 100 on the head section 92 maybe used to sense the amount of force being applied by the nosepiece 116during both the learning and ply forming processes.

As can be appreciated from the foregoing description, the former 40provides 2-axis (Y-Z) controlled sweeping of pre-preg plies with 2-axiscoordinated motion. However, motion is not limited to 2 axes. Forexample, the required motion may be accomplished using multiple robots(not shown) operating in unison. The adaptive control employed by former40 allows the former modules 42 to adapt to each particular tool 48 usedto make any of a number of parts within a family of parts, by using ageneric profile of the parts in the family, and force feedback to learnand follow the specific tool and part geometry. The adaptive controlused by the former 40 also automatically adapts or adjusts to the shapeof the part 54 as the thickness of the part 54 increases with layup ofeach successive ply 46. The use of a combination of position control andmotor torque feedback allow constant pressure to be applied by thenosepiece 116 to the part 54 during the forming process.

As shown in FIG. 7, the tool 48 may be supported on a wheeled cart 126for movement into proximity with a former 40 comprising a plurality offormer modules 42 that have been configured to substantially match thegeometry of the tool 48. The former modules 42 are rigidly connectedtogether by mechanical linkages 44 (see FIG. 8) between bases 106 ofadjacent former modules 42. Referring particularly to FIG. 9, the plycarrier control assembly 86 (FIG. 6) includes a Z-axis slide supportallowing movement of the support arm 95 (see FIGS. 6-8) along the Zaxis, and a slide 130 providing movement of the support arm 95 along theY-axis. Tool clamps 114 driven by air cylinders 136 function to clampthe flange 82 (FIG. 5) of the tool 48 against an index plate 132 whichestablishes a common “waterline” or reference datum, for all of theformer modules 42, automatically aligning all of the former modules 42relative to the tool 48. Each of the former modules 42 includes a slightamount of “float” that allows each of the head sections 92 to align tothe tool waterline and then lock into position. As a result of thisfeature, the tool 48 does not have to be located on a precise platform,and the forming process can be carried out on standard factory floorsthat may be uneven. Although not shown in the drawings, the tool 48and/or the plies 46 may be heated during a layup process in order tosoften the resin and facilitate forming. Heating may be achieved usingany suitable technique, including but not limited to infrared radiationusing IR heat lamps.

Referring to FIG. 10, the ply carrier 84 may be formed of a flexible,durable material that may be stretchable in one or more directions, forexample along its width “W”. One or more plies 46 may be placed inpreselected, indexed positions on the ply carrier 84 prior to the plycarrier 84 being loaded onto the former 40. The ply carrier 84 mayinclude upper and lower carrier guides 140, 142 that are used toremovably mount the ply carrier on the former 40. For example, the uppercarrier guide 140 may include individual guide members (not shown) onthe back of the ply carrier 84 which are received within a groove (notshown) in the carrier support track 120. Similarly, the lower carrierguide 142 may comprise a continuous guide strip (not shown) on the backof the ply carrier 84 which is received within a groove (not shown)extending along the inner chord clamp 122.

FIG. 11 illustrates further details of one embodiment of the nosepiecetrack 118. In this example, the nosepiece track 118 comprises aplurality of spaced apart segments 144 which allow the nosepiece track118 to flex as required to permit the nosepiece 116 to conform tofeatures of the tool 48. As shown in FIG. 12, the nosepiece 116 includesan outer forming tip 146 that has a profile suited for the particularapplication and features of the tool 48. The nosepiece 116 is mounted onthe nosepiece track 118 by a T-shaped guide 148 that is slidablyreceived within a groove 145 in the nosepiece track 120. The nosepiece116 may be removably installed in the nosepiece track 120 by sliding itlengthwise through the groove 145. Thus, nosepieces 116 having differentsizes and shapes are interchangeable, allowing selection of a nosepiece116 that is suitable for the application and tool shape. The nosepiece116 may be compliant in order to better conform it to features of thetool 48 during the forming process.

FIG. 13 broadly illustrates the steps of a method of fabricating each ofthe plurality of differing parts 54 in a family 56 of parts 54 havingcommon features, wherein each of the parts 54 is fabricated using aunique tool 48. Beginning at 154, identical fabrication modules 42 arearranged to match a tool 48 in which the part 54 to be fabricated. At156, each of the fabrication modules 42 is adapted to a local section ofthe tool 48. At 158, operation of the fabrication modules 42 iscontrolled and coordinated to fabricate portions of the part 54 over acorresponding section of the tool 48.

FIG. 14 broadly illustrates the steps of a method of fabricating acomposite laminate structure 54. Beginning at 160, a plurality offorming modules 42 are arranged to match a tool 48 on which thestructure 54 is to be formed. At 162, the modules 42 are linked togetherto form a single former 40 for forming the entire composite laminatestructure 54. At 164, a continuous forming member 116 is mounted on theforming modules 42. The forming member 116 defines a spline extendingsubstantially the entire length of the former 40. At 166, the formingmember 116 is used to form and compact composite plies 46 on the tool48.

Attention is now directed to FIG. 15 which broadly illustrates the stepsthat may be carried out to set up and teach each of the forming modules42 in preparation for a forming process using a particular tool 48. At168, former 40 is set up by arranging and linking former modules 42together using linkages 44, and initializing settings of each of themodules 42. Then, at 170, the linked former modules 42 are moved toengage and lock onto the tool 48. The tool clamps 114 (FIG. 9) clamp theflange 82 (FIG. 5) of the tool 48 against the tool waterline index plate132. The former modules 42 are aligned to match the curvature of thetool 48, and the linkage 44 maintains the shape and alignment of theformer modules 42. At 172, the former module 42 is taught the positionof the inner chord clamp relative to the tool 48, and at 174 theposition of the nosepiece relative to the tool 48 is learned. At 176,the servo-motors 94 (FIG. 6) and the encoders 96 are used to initiallylearn the shape of the tool, and then to relearn the surface of thelaminated plies 46 as each of the plies 46 is laid up.

Attention is now directed to FIGS. 16 and 17 which illustrate additionaldetails of the disclosed forming method. Beginning at 178 (FIG. 17), thetool 48 is moved into proximity to the former 40, and at 180, the tool48 is clamped to the former 40. At 182, one or more plies 46 are mountedon the ply carrier 84. At 184, the ply carrier 84 having the ply 46mounted thereon is loaded onto the former 40. This loading process isperformed by inserting the lower carrier guide 142 into the former 40 at186, and at step 188, inserting the upper guide 140 into the upper guiderail track, such as carrier support track 120, on the former 40. At 190,the position of the nosepiece 116 along the Y-axis is determined bydriving the nosepiece 116 forward along the Y-axis into contact with theinner chord tool flange 72 using a predetermined motor torque. Anencoder 96 coupled with the servo-motor 94 is read to indicate theposition of the nosepiece 116. At 192, the nosepiece 116 is pressedagainst the inner chord flange with a predetermined amount of force. At194, the nosepiece 116 is moved upwardly along the Z-axis at apredetermined rate. The ply 46 is swept and compacted against thesurface of inner chord tool flange 72, at step 194.

At 196, the transition of the nosepiece 116 from the inner chord toolflange 72 to the web tool surface 76 is sensed by monitoring a Y-axisencoder 96 for a change. At 198 control of the nosepiece 116 along theY-axis is switched from a torque mode to a position mode, and along theZ-axis from a position mode to a torque mode. The nosepiece 116maintains compaction pressure against the ply 46 during the transitionover the inside corner of the inner chord tool radius 74. At 200, thenosepiece 116 sweeps and compacts the ply against the web tool surface76 on the tool 48. At 202, movement of the nosepiece 116 is terminatedwhen the nosepiece 116 is a short distance from the shear tie radius 78.At 204, the nosepiece 116 is used to “discover” the shape of the sheartie radius 78. This is accomplished by advancing the nosepiece 116 alongthe Y-axis until a preselected torque limit is reached. At step 206,control of the nosepiece 116 is switched to the torque mode along theY-axis and along the Z-axis. At 208, the nosepiece 116 sweeps andcompacts apply against the shear tie tool surface 80. During this step,the nosepiece 116 applies force along the Y-axis in the torque mode,while being driven upwardly along the Z-axis in the position mode. Atstep 210 the ply forming process is complete and steps 182-208 may berepeated to layup, form and compact additional plies.

Embodiments of the disclosure may find use in a variety of potentialapplications, particularly in the transportation industry, including forexample, aerospace, marine, automotive applications and otherapplication requiring automated fabrication of a variety of parts withina family of parts having common features or characteristics. Thus,referring now to FIGS. 18 and 19, embodiments of the disclosure may beused in the context of an aircraft manufacturing and service method 212as shown in FIG. 18 and an aircraft 214 as shown in FIG. 19. Aircraftapplications of the disclosed embodiments may include, for example,without limitation, fuselage frame sections, spars, stringers and otherstructural members, to name only a few. During pre-production, exemplarymethod 212 may include specification and design 216 of the aircraft 214and material procurement 218. During production, component andsubassembly manufacturing 220 and system integration 222 of the aircraft214 takes place. Thereafter, the aircraft 214 may go throughcertification and delivery 224 in order to be placed in service 226.While in service by a customer, the aircraft 214 is scheduled forroutine maintenance and service 228, which may also includemodification, reconfiguration, refurbishment, and so on.

Each of the processes of method 212 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof vendors, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 19, the aircraft 214 produced by exemplary method 212may include an airframe 230 with a plurality of systems 232 and aninterior 234. Examples of high-level systems 232 include one or more ofa propulsion system 236, an electrical system 238, a hydraulic system240, and an environmental system 242. Any number of other systems may beincluded. Although an aerospace example is shown, the principles of thedisclosure may be applied to other industries, such as the marine andautomotive industries.

Systems and methods embodied herein may be employed during any one ormore of the stages of the production and service method 212. Forexample, components or subassemblies corresponding to production process220 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 214 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 220 and 222, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 214. Similarly, one or more of apparatus embodiments, methodembodiments, or a combination thereof may be utilized while the aircraft242 is in service, for example and without limitation, to maintenanceand service 228.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different advantages as compared to otherillustrative embodiments. The embodiment or embodiments selected arechosen and described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. An apparatus for fabricating each of a pluralityof differing laminate structures in a family of structures having commonfeatures, comprising: a plurality of separate fabrication modules eachlocally adapted to fabricate a section of the laminate structure on acorresponding tool, the fabrication modules being reconfigurable tofabricate each of the laminate structures in the family thereof, whereineach of the fabrication modules includes a track in which a portion of aforming member is local mounted; the forming member adapted for forminglaminate plies over the tool, the forming member extending along alength of the fabrication modules, portions of the forming member beingmounted on each of the fabrication modules for movement over the toolalong at least two axes, wherein the forming member is removably mountedin the tracks to allow interchangeability of a plurality of formingmembers respectively having different shapes; and a controller forcontrolling and coordinating automated operation of the fabricationmodules.
 2. The apparatus of claim 1, wherein the forming member iscontinuous along the length of the fabrication modules.
 3. The apparatusof claim 1, wherein the forming member is adapted to sweep laminateplies over the tool, and includes compliance.
 4. The apparatus of claim1, wherein each of the fabrication modules includes a clamp adapted forclamping a portion of a laminate ply against a portion of the tool. 5.The apparatus of claim 1, wherein each of the fabrication modulesincludes a powered drive coupled with the forming member for sweepingthe forming member over the laminate plies and compacting laminate plieson the tool.
 6. The apparatus of claim 1, further comprising: a flexibleply carrier adapted to hold at least one laminate ply thereon, andwherein each of the fabrication modules includes a pair of spaced aparttracks adapted to releasably hold the ply carrier, and a ply carriercontrol assembly for holding the ply carrier in tension as the formingmember forms the ply over the tool.
 7. The apparatus of claim 6,wherein: the forming member is engageable with the ply carrier to sweepthe ply carrier along with the ply thereon over the tool, and the plycarrier control assembly includes drives for adjusting a position of theply carrier along two axes.
 8. The apparatus of claim 1, wherein each ofthe fabrication modules further includes: a force sensor for sensing alevel of force applied to the laminate plies by the forming member, anda position sensor for sensing the position of the forming member.
 9. Theapparatus of claim 1, wherein each of the fabrication modules includes aclamp for clamping the fabrication module to the tool.
 10. The apparatusof claim 1, further comprising: linkage between the fabrication modulesfor rigidly coupling the fabrication modules together and for aligningthe fabrication modules relative to the tool.
 11. The apparatus of claim1, wherein the fabrication modules are substantially identical andinterchangeable with each other.
 12. The apparatus of claim 1, furthercomprising a central controller for controlling and coordinating theoperation of the fabrication modules to collectively fabricate thelaminate structure.
 13. A method of fabricating each of a plurality ofdiffering parts in a family of parts having common features, whereineach of the parts is fabricated using a unique tool, comprising:arranging a plurality of separate, substantially identical fabricationmodules to substantially match a tool on which one of the parts is to befabricated, wherein each of the fabrication modules includes a track;locally mounting portions of a forming member within the track alongsubstantially the entire length of the fabrication modules, the portionsof the forming member being mounted on each of the fabrication modulesfor movement over the tool along at least two axes, wherein the formingmember is removably mounted in the tracks to allow interchangeability ofa plurality of forming members respectively having different shapes;adapting each of the fabrication modules to a local section of the tool;and, controlling and coordinating operation of the fabrication modulesto fabricate portions of the part over a corresponding section of thetool.
 14. The method of claim 13, wherein arranging the fabricationmodules includes: moving each of the fabrication modules into proximityto the tool, and rigidly linking the fabrication modules together. 15.The method of claim 13, further comprising: clamping each of thefabrication modules to the tool.
 16. The method of claim 13, whereinadapting the each of the fabrication modules includes learning, by eachof the fabrication modules, the location of surfaces on the tool onwhich the part is to be fabricated.
 17. The method of claim 16, furthercomprising: sweeping materials across the surfaces of the tool using theforming member, and using the forming member to learn the location ofthe surfaces on the tool.
 18. The method of claim 17, wherein learningthe location of the surfaces includes: sensing a position of the formingmember as the forming member sweeps materials across the surfaces of thetool, and recording the sensed position of the forming member.
 19. Themethod of claim 13, wherein adapting each of the fabrication modulesincludes adjusting the elevation of the fabrication modules to a commonwaterline.
 20. The method of claim 13, wherein the step of locallymounting portions of the forming member within the track alongsubstantially the entire length of the fabrication modules furthercomprises: forming a continuous spline defined by the forming memberalong all of the fabrication modules.
 21. The method of claim 13,wherein: each of the fabrication modules is a laminate ply formermodule, and arranging the fabrication modules includes linking thefabrication modules together to form a single laminate ply former. 22.An apparatus for fabricating each of a plurality of differing laminatestructures in a family of structures having common features, comprising:a flexible ply carrier adapted to hold at least one laminate plythereon; a plurality of separate fabrication modules each locallyadapted to fabricate a section of the laminate structure on acorresponding tool, wherein each of the fabrication modules includes apair of spaced apart tracks adapted to releasably hold the ply carrier,the fabrication modules being reconfigurable to fabricate each of thelaminate structures in the family thereof; a forming member adapted forforming laminate plies over the tool, the forming member extending alonga length of the fabrication modules, portions of the forming memberbeing mounted on each of the fabrication modules for movement over thetool along at least two axes; a ply carrier control assembly for holdingthe ply carrier in tension as the forming member forms the ply over thetool; and a controller for controlling and coordinating automatedoperation of the fabrication modules.
 23. The apparatus of claim 22,wherein the forming member is continuous along the length of thefabrication modules.
 24. The apparatus of claim 23, wherein each of thefabrication modules includes a track in which a portion of the formingmember is locally mounted.
 25. The apparatus of claim 24, wherein theforming member is removably mounted in the tracks to allowinterchangeability of a plurality of forming members respectively havingdifferent shapes.
 26. The apparatus of claim 22, wherein the formingmember is adapted to sweep laminate plies over the tool, and includescompliance.
 27. The apparatus of claim 22, wherein each of thefabrication modules includes a clamp adapted for clamping a portion of alaminate ply against a portion of the tool.
 28. The apparatus of claim22, wherein each of the fabrication modules includes a powered drivecoupled with the forming member for sweeping the forming member over thelaminate plies and compacting laminate plies on the tool.
 29. Theapparatus of claim 22, wherein: the forming member is engageable withthe ply carrier to sweep the ply carrier along with the ply thereon overthe tool, and the ply carrier control assembly includes drives foradjusting a position of the ply carrier along two axes.
 30. Theapparatus of claim 22, wherein each of the fabrication modules furtherincludes: a force sensor for sensing a level of force applied to thelaminate plies by the forming member, and a position sensor for sensingthe position of the forming member.
 31. The apparatus of claim 22,wherein each of the fabrication modules includes a clamp for clampingthe fabrication module to the tool.
 32. The apparatus of claim 22,further comprising: linkage between the fabrication modules for rigidlycoupling the fabrication modules together and for aligning thefabrication modules relative to the tool.
 33. The apparatus of claim 22,wherein the fabrication modules are substantially identical andinterchangeable with each other.
 34. The apparatus of claim 22, furthercomprising a central controller for controlling and coordinating theoperation of the fabrication modules to collectively fabricate thelaminate structure.
 35. A method of fabricating each of a plurality ofdiffering parts in a family of parts having common features, whereineach of the parts is fabricated using a unique tool, comprising:arranging a plurality of separate, substantially identical fabricationmodules to substantially match a tool on which one of the parts is to befabricated, wherein each of the fabrication modules includes a pair ofspaced apart tracks, the tracks having a ply carrier held thereon;locally mounting portions of a forming member within the track alongsubstantially the entire length of the fabrication modules, the portionsof the forming member being mounted on each of the fabrication modulesfor movement over the tool along at least two axes; adapting each of thefabrication modules to a local section of the tool; and, holding the plycarrier in tension on the tracks while the forming member forms a plyover the tool; controlling and coordinating operation of the fabricationmodules to fabricate portions of the part over a corresponding sectionof the tool.
 36. The method of claim 35, wherein arranging thefabrication modules includes: moving each of the fabrication modulesinto proximity to the tool, and rigidly linking the fabrication modulestogether.
 37. The method of claim 35, further comprising: clamping eachof the fabrication modules to the tool.
 38. The method of claim 35,wherein adapting the each of the fabrication modules includes learning,by each of the fabrication modules, the location of surfaces on the toolon which the part is to be fabricated.
 39. The method of claim 38,further comprising: sweeping materials across the surfaces of the toolusing the forming member, and using the forming member to learn thelocation of the surfaces on the tool.
 40. The method of claim 39,wherein learning the location of the surfaces includes: sensing aposition of the forming member as the forming member sweeps materialsacross the surfaces of the tool, and recording the sensed position ofthe forming member.
 41. The method of claim 35, wherein adapting each ofthe fabrication modules includes adjusting the elevation of thefabrication modules to a common waterline.
 42. The method of claim 35,wherein the step of locally mounting portions of the forming memberwithin the track along substantially the entire length of thefabrication modules further comprises: forming a continuous splinedefined by the forming member along all of the fabrication modules. 43.The method of claim 35, wherein: each of the fabrication modules is alaminate ply former module, and arranging the fabrication modulesincludes linking the fabrication modules together to form a singlelaminate ply former.